Gasifier Throat Cooling Element Design
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Solution Overview
Problem
Refractory materials in the gasifier throat are degraded due to high temperatures and aggressive chemistry, necessitating frequent replacement and costly shutdowns.
Innovation Solution
A gasifier system with a cooling cavity containing cylindrical cooling coils surrounded by refractory material, connected to a coolant inlet and outlet, maintains thermal contact with the throat refractory to manage heat transfer and extend refractory life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If refractory material is used to protect the throat, then the pressure vessel wall is protected from high temperature and aggressive chemistry, but the refractory material degrades over time requiring frequent replacement
Solution Approach 1:
The cooling element is installed behind the refractory material before operation begins, pre-cooling the refractory structure and maintaining its temperature throughout operation. This preliminary cooling action prevents the refractory from degrading due to extreme thermal exposure, extending its service life while maintaining vessel wall protection.
Solution Approach 2:
A cooling element serving as an intermediary component is positioned between the external environment and the refractory material. This intermediary absorbs excess heat through coolant circulation, protecting the refractory from direct thermal exposure and chemical degradation, thereby extending its operational lifespan while maintaining protection functionality.
2Reliability
If refractory material is periodically replaced, then degraded material is removed and replaced, but costly shutdowns are required
Solution Approach 1:
The cooling system is installed and activated before refractory degradation occurs, continuously managing thermal exposure. This preliminary and ongoing protection prevents the need for frequent refractory replacement, eliminating planned shutdowns for maintenance while maintaining throat lining integrity throughout extended operational periods.
3Duration of action of stationary object
If cooling element is added behind refractory, then refractory temperature is controlled extending its life, but device complexity increases
Solution Approach 1:
The cooling element serves multiple functions simultaneously: it cools the refractory material to extend service life, protects the pressure vessel wall from thermal exposure, and provides a structural support framework. This multi-functionality justifies the added complexity by delivering multiple benefits from a single integrated component.
Solution Approach 2:
The cooling element is nested within the existing gasifier structure, positioned in the space behind the refractory material. This nested configuration utilizes available space efficiently, integrating the cooling function into the existing design without requiring extensive structural modifications, thereby limiting the increase in overall device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system reduces refractory degradation, extending its lifespan and minimizing shutdowns by controlling coolant temperature and pressure to match refractory conditions, thus improving operational efficiency and reducing maintenance costs.
Implementation Method 1
the cooling element is in thermal contact with the throat refractory material on the inner face, the top face, and the outer face
Implementation Method 2
A method of operating a gasifier comprising indirectly transferring heat from a refractory material having a refractory temperature to a coolant having a coolant temperature
Data Source
AI summary
A gasifier for converting a carbonaceous feedstock to produce syngas comprising a cone section and a throat section; wherein the throat section comprises a throat refractory material having an inside surface and a substantially cylindrical cooling element having an inner face and an outer face in a radial direction, and a top face and a bottom face in the vertical direction, wherein the inner, outer, top, and bottom faces define a cooling cavity; and wherein the cooling element is in thermal contact with the throat refractory material on the inner face, the top face, and the outer face.